Print quality setup using banks in parallel

ABSTRACT

The present invention embraces a method and apparatus for an efficient and economical print quality setup for thermal printers. A thermal printhead of a thermal printer constitutes multiple printhead banks. The printhead banks may be controlled by strobe signals. While configuring print quality, each of the strobe signals may operate separately with different power causing the printhead banks to operate in different configurations while printing an identical pattern. As each the banks are operating in different configuration, they each print the identical pattern with a different print quality. One print quality may be selected from the different quality patterns printed by each printhead bank on a single printed label or media. The selected quality pattern corresponds to a quality factor. The method may reduce the time to select a configuration and may reduce the amount of usage of media or labels.

FIELD OF THE INVENTION

The present invention relates to improvements in printers, and more particularly, to improvements in the print quality setup of a thermal printer.

BACKGROUND

Generally speaking the print quality setup of a thermal printer may be difficult, time consuming and may waste expensive labels. One typical approach of determining the print quality setup includes printing labels with different settings and allowing the user to manually select the best label. This procedure may waste many labels and is very undesirable especially if the labels are expensive. Another approach entails analyzing the media (paper and ribbon) and determining the composition of the printed label. This approach adds the expense of an analyzer and associated software to the system. In yet another approach, an electronic or visual ID is positioned on the media and the print quality setup is based predetermined settings. This approach may require validation of all possible media to be used on the printer and would not support unknown media.

Therefore, a need exists for an efficient and inexpensive solution for the print quality setup of thermal printers.

SUMMARY

Accordingly, in one aspect, the present invention embraces a method and apparatus for an efficient and economical print quality setup for thermal printers. A thermal printhead of a thermal printer constitutes multiple printhead banks. The printhead banks are controlled by strobe signals.

In an exemplary embodiment, a printer may comprise a set of printhead banks, wherein each of the set of printhead banks is operable to independently print an identical pattern with a different print quality on a media; a processor capable of generating a strobe signal for each of the set of printhead banks based on a quality factor, wherein the quality factor determines the print quality for each of the identical patterns on the media, wherein the processor selects the quality factor based on a user selection of a preferred pattern; and the media comprising a set of the identical patterns, each with different print quality, each printed by a different printhead bank. The processor sends a corresponding strobe signal and data signal to a corresponding printhead bank of the set of printhead banks. The placement of the printer in a normal print mode of operation causes the set of printhead banks to print media based on the quality factor corresponding to the preferred pattern selection.

An algorithm of the processor may analyze the selected preferred pattern and determines whether to tune” the quality factor associated with the preferred pattern. If the algorithm of the processor decides to tune the quality factor associated with the preferred pattern, the processor generates another set of quality factors based on the preferred pattern selection as a seed. The processor then proceeds to select same or another preferred pattern based on the another set of quality factors. The preferred pattern selection is aided or automated by a scanner and processor software. The processor may independently control the quality factor associated with each strobe signal.

In another exemplary embodiment, a method for printing may comprise the steps of: receiving, by a processor of a printer, a prompt from a user to start a print quality factor setup including a generation of a set of N quality factors, wherein a quality factor determines a print quality of a pattern of a media; generating, by the processor of the printer, a set of N strobe signals corresponding to the set of N quality factors; and transmitting, by the processor of the printer, each of the set of the N strobe signals and each of an associated set of N data signals to each of a corresponding set of N printhead banks. Each of the N printhead banks print a specific pattern and collectively print N patterns on the media. The user reviews the N patterns on the media and selects a preferred pattern based on the print quality.

In another aspect, the present invention embraces a strobe signal that may comprise sequence of variable length pulses that controls an amount of energy applied to resistive elements of printhead of the printer. Also, the processor of the printer may determine whether to tune the quality factor based on an analysis of the quality factor of the selected preferred pattern.

The foregoing illustrative summary, as well as other exemplary objectives and/or advantages of the invention, and the manner in which the same are accomplished, are further explained within the following detailed description and its accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an exemplary embodiment of a system that provides an efficient print quality setup.

FIG. 2 illustrates an exemplary flowchart for a method that provides an efficient print quality setup.

FIG. 3 illustrates an exemplary image of label comprising four separate patterns.

DETAILED DESCRIPTION

The present invention embraces a method and apparatus for an efficient and economical print quality setup for thermal printers. A thermal printhead of a thermal printer constitutes multiple printhead banks. The printhead banks are controlled by strobe signals. In a print quality setup operation, the strobe lines from all the banks may be combined and applied with one power signal resulting in a constant print quality throughout all of the printhead banks. This means that all of the printhead banks may be printing with the same print quality. During print quality setup, excessive labels must be printed to select the preferred print quality. As used herein, “strobe signals” are transmitted on the “strobe line”. As used herein, a “label” is a type of “media”.

For the present invention, while configuring print quality, all the strobe lines may operate separately with different power signals causing the printhead banks to operate in different configurations. As all the banks are operating in different configurations, one print quality may be selected from the given options or patterns printed by each printhead bank on a single printed label. The selected pattern corresponds to a quality factor. The method may reduce the time to select a configuration and may reduce the amount of usage of labels.

Further, the selected configuration, based on a specific quality factor, may be loaded to the connected strobe lines for normal printing operation. In other words, the method and apparatus for print quality setup may be based on independently controlling the strobe signals for the printhead banks to produce the printing of a different print quality from each bank. Then, selecting a preferred print quality pattern and loading the corresponding quality factor to a connected strobe line for normal print operation. In the present invention, the print quality setup is based on quality factors and may be referred to as a print quality factor setup.

FIG. 1 illustrates an exemplary embodiment of a system 100 for providing an efficient print quality setup that results in achieving a high print quality without printing excessive labels. System 100 may comprise printer 102 and scanner 104 (optional). System 100 is operated by user 101. Printer 102 comprises processor 106, printhead banks 108 and label 110. Printhead banks 108 may comprise N banks including bank1 121, bank2 122, bank3 123, bank4 124, . . . bankN 125. Label 110 may comprise N data patterns including pattern_A 141, pattern_B 142, pattern_C 143, pattern_D 144, . . . pattern_Nth 145. In operation, processor 106 may receive a prompt from user 101 to start a setup of quality factors. The quality factors represent a print quality specification.

In response to receiving the prompt, processor 106 may generate and transmit N data patterns and N strobe signals to the printhead banks 108. The N strobe signals may comprise strobe1 111, strobe2 112, strobe3 113, strobe4 114, . . . strobeN 115. The N data patterns may comprise data1 116, data2 117, data3 118, data4 119, . . . dataN 120. Each of the N data patterns and N strobe signals may be coupled to a corresponding one of the printhead banks 108. That is, strobe1 111 may be coupled to bank1 121, strobe2 may be coupled to bank2 122, etc.

Each of the N strobe signals define a quality factor corresponding to a pattern that may be printed on label 110. The strobe signal may comprise a sequence of variable length pulses, typically a sequence from 1 to 6 pulses per single dot line. The duration of pulses may be from 10's of microseconds to 100's of microseconds. This pulse specification may control the amount of energy going into resistive elements (dots) of the printhead, thus variably heating up the elements causing thermal paper to react or ribbon to melt.

Dot line is a single line of dots produced by the printhead on the paper. Printing involves producing multiple dot lines sequentially to create an image as the paper moves forward.

Returning the FIG. 1, each bank in the printhead banks 108 receives a quality factor via a strobe signal that results in a corresponding pattern to be printed on a label. For example, bank1 121 receives a quality factor via strobe1 111. Based on this quality factor, bank1 121 generates a heat profile print_A 131 that results in pattern_A 141 being printed as a part of label 110. Likewise, bank2 122 receives another quality factor from strobe2 112. Based on this another quality factor, bank2 122 generates a heat profile print_B 132 that results in pattern_B 142 being printed as a part of label 110. BankN 125 receives yet another quality factor from strobeN 115. Based on this yet another quality factor, bankN 125 generates a heat profile print_Nth 135 that results in pattern_N 145 being printed as a part of label 110. The remaining banks, illustrated in FIG. 1, have corresponding heat profiles Print_C 133 and Print_D 134. Label 110 comprises N patterns, each reflecting a different quality factor as specified by each of the N strobe signals. Each of the set of printhead banks 108 independently prints an identical pattern on a label.

Once label 110 is printed, a user 101 may review the patterns on label 110 and select a preferred pattern. The preferred pattern corresponds to a specific quality factor. For example, the preferred pattern may be pattern_B 142. After making this selection, user 101 may proceed with conventional printing based on the preferred pattern, pattern_B 142. Or, in a second cycle, a printer processor algorithm may determine if further tuning of the quality factors is necessary. Processor 106 may tune the selection and proceed to generate another set patterns based on the quality factor of the preferred pattern as a seed, e.g., pattern_B 142. This another set of patterns that are printed on label 110 would result in the printing the following set of patterns: pattern_B1, pattern_B2, pattern_B3, etc. (these patterns are not shown on FIG. 1). User 101 may select a preferred pattern from the second cycle set of patterns, e.g., pattern_B3, and proceed with conventional printing. Or, the user may proceed with a third cycle of tuning, and generate yet another label 110 based on pattern_B3. The action may result in a set of patterns, pattern_B31, pattern-B32, pattern_B34, etc. (These patterns are not shown on FIG. 1). As in prior cycles, once label 110 is printed, a user 101 may review the patterns on label 110 and select same or another preferred pattern. After making this selection, user 101 may proceed with conventional printing based on the preferred pattern, or the user may proceed with yet another cycle of tuning or “fine tuning”. For each cycle of “fine tuning”, the user repeats the steps of executing print quality setup and prints another multi-pattern label for review and re-selection of a preferred pattern. This procedure can further improve the print quality of the label 110.

In summary, processor 106 independently controls the bank strobe signals (transmitted on the strobe lines) to allow the printhead banks 108 to print a different print quality at each bank. FIG. 3 illustrates an exemplary image of a label comprising four separate patterns, i.e., a multi-pattern label.

N is a number having a value of at least 2. The previous describe procedure may have M cycles of tuning or “fine tuning”. Without the utilization of independent strobe control for each bank, the print quality factor setup may require up to N times as many labels and N times as much time to achieve the same result. So, for j patterns of “fine turning”, the procedure may save j*(N−1) labels.

As an alternative to user 101 independently selecting the preferred pattern, a scanner may scan label 110 and provide the scan of label 110 to processor 106. With printer processor algorithms, processor 106 may analyze the scan of label 110 and aids or automates the user in the selection of a preferred pattern. Based on either a decision from user 101 or a decision by processor 106, processor 106 proceeds to conventional printing of the preferred pattern, or proceeds to a cycle of “fine tuning” based on the preferred pattern as the seed.

FIG. 2 illustrates an exemplary flowchart 200 for a method that provides an efficient print quality setup to achieve a high print quality without printing excessive media or labels. The method may comprise the following steps:

User prompts printer to start a print quality factor setup and generate a set of N quality factors. (step 202)

Based on the set of N quality factors, a processor of the printer generates a set of N strobe signals corresponding to the set of N quality factors. (step 204)

Based on the set of N strobe signals, the processor transmits each of the N strobe signals to a corresponding set of N printhead banks together with data corresponding to a pattern for each portion of a media or label. (step 206)

Each of the N printhead banks prints a portion of a media or label controlled by one of the N quality factors. (step 208)

Does the user independently review N printed patterns on the media or label and select a preferred pattern? If yes, the user selects a preferred pattern. (step 210)

If no, a scanner and processor software analyze N printed patterns and aids or automates the user in the selection of a preferred pattern. (step 212)

With the preferred pattern selection, does an algorithm in printer processor determine if further fine tuning of the quality factors is necessary? (step 214)

If no, the printer is setup for a quality factor corresponding to the preferred pattern selection. (step 218)

If yes, the processor of the printer generates another set of N quality factors based on the preferred pattern selection as a seed. (step 216)

The method then repeats step 206 and cycles to select another preferred pattern.

FIG. 3 illustrates an exemplary image of label 300 comprising four separate patterns, i.e., a multi-pattern label. Label 300 is printed based on step 208 of FIG. 2. Label 300 comprises Pattern_A—141 which was printed by Bank1—121, Pattern_B—142 which was printed by Bank2—122, Pattern_C—143 which was printed by Bank3—123, and Pattern_D—144 which was printed by Bank4—124.

To supplement the present disclosure, this application incorporates entirely by reference the following commonly assigned patents, patent application publications, and patent applications:

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In the specification and/or figures, typical embodiments of the invention have been disclosed. The present invention is not limited to such exemplary embodiments. The use of the term “and/or” includes any and all combinations of one or more of the associated listed items. The figures are schematic representations and so are not necessarily drawn to scale. Unless otherwise noted, specific terms have been used in a generic and descriptive sense and not for purposes of limitation. 

The invention claimed is:
 1. A printer, comprising: a set of printhead banks, wherein each of printhead banks in the set of printhead banks is operable to independently print an identical pattern with a different print quality on a media; a processor operable to: generate a strobe signal for each of the printhead banks in the set of printhead banks based on a quality factor, wherein the quality factor determines the print quality for each of the identical patterns on the media; and transmit a corresponding strobe signal and data signal to a corresponding printhead bank of the set of printhead banks, wherein each of the set of printhead banks prints a set of identical patterns, each with different print quality, on the media.
 2. The printer according to claim 1, wherein the processor receives an indication of a preferred pattern based on the print quality.
 3. The printer according to claim 1, wherein the processor independently controls the quality factor associated with each strobe signal.
 4. The printer according to claim 2, wherein a selection of the preferred pattern is aided or automated by a scanner and processor software.
 5. The printer according to claim 2, wherein a placement of the printer in a normal print mode of operation causes the set of printhead banks to print on the media based on the quality factor corresponding to the preferred pattern.
 6. The printer according to claim 2, wherein the processor analyzes the selected preferred pattern and determines whether to tune the quality factor based on the print quality associated with the preferred pattern.
 7. The printer according to claim 6, wherein, if the processor decides to tune the quality factor, the processor generates another set of quality factors based on the preferred pattern as a seed.
 8. The printer according to claim 7, wherein the processor then proceeds to select same or another preferred pattern based on the another set of quality factors.
 9. The printer according to claim 2, wherein the processor modifies the quality factor based on an analysis of the print quality of the preferred pattern.
 10. A method, comprising: generating, by a processor of a printer, a strobe signal for each of printhead banks in a set of printhead banks operable to independently print an identical pattern with a different print quality on a media, wherein the strobe signal is generated based on a quality factor that determines a print quality for each of the identical patterns on the media; and transmitting, by the processor of the printer, a corresponding strobe signal to a corresponding printhead bank of the set of printhead banks, wherein each of the set of printhead banks print a set of the identical patterns, each with different print quality, on the media.
 11. The method of claim 10, further comprising: receiving, by the processor of the printer, an indication of a preferred pattern based on the print quality.
 12. The method of claim 11, further comprising: modifying, by the processor of the printer, the quality factor based on an analysis of the print quality of the preferred pattern.
 13. The method of claim 12, further comprising: determining, by the processor of the printer, that the printer is operating in a normal printing mode; and causing, by the processor of the printer, the set of printhead banks to print on the media based on the modified quality factor corresponding to the preferred pattern.
 14. The method of claim 11, further comprising generating, by the processor of the printer, another set of quality factors based on the preferred pattern as a seed.
 15. The method of claim 14, further comprising selecting, by the processor of the printer, same or another preferred pattern based on the another set of quality factors.
 16. The method of claim 15, wherein the selection is aided or automated by a scanner and processor software.
 17. The method of claim 10, wherein generating the strobe signal based on the quality factor further comprises, independently controlling, by the processor of the printer, the quality factor associated with the strobe signal. 